Some basic questions to be asked when designing power distribution systems

1. What is the nature and magnitude of the electrical loads?

Until the process and load requirements are known, one cannot intelligently lay out a power system
to meet the load requirements.
2. Where are the loads located?
One should know the exact location of the electrical loads on the plot plan, in order to be able to
plan the cable routing and layout. This will also help in locating the sub-station optimally economi!e
the cable length".
3. Where is the power coming from? How much will the power system cost?
The power could be deri#ed from the electric power grid, from some existing nearby sub-station or
generated within the plant in-plant generation". The decision depends on a#ailability of the power
from the grid or the existing facility and on the economics. Sometimes the in-plant generation could
be more reliable and economic if the grid power requires long transmission line or the existing sub-
station is too far. Sometimes the grid power could be #ery unreliable, as it happens in some
de#eloping countries. This is when in-plant generation will certainly be more reliable and
ad#antageous.
4. What voltage levels should be selected for the plant primary distribution, high voltage motors and
the low voltage systems?
The factors generally considered for the primary distribution system are the #oltage at which
incoming power of the plant is a#ailable, large motors requiring high #oltage, flexibility, si!e of the
plant, economics, etc. primary distribution #oltages could be $$k%, &&k%, '.'k%, $.$k%, out of which
'.'k% and $.$k% are also used for high #oltage motors. (ow #oltage systems are generally )&* % or
$+, %, $- phase )- wire systems. The low #oltage systems are generally )-wire systems, to allow &-
phase supplies to be deri#ed.
. What type of distribution scheme configuration is best suited for the plant? !adial, ring mains,
redundant feeders "2 # 1$$%& with manual or auto change over schemes?
-hile designing the distribution scheme, #arious aspects should be kept in mind, like reliability
dictated by the nature of the process", economics, future load growth, pro#ision for maintenance
say, when one generator or transformer is under maintenance, it should still be possible to supply
full plant load", flexibility, etc.
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'. How is the si(e of indoor sub)station determined?
The si!e of the sub-station is determined by the si!e of equipment located in it. The ma.or
equipments located inside sub-station are switchgears, control panels if required", /0 and 10
U2S, batteries in separate rooms, if #ented type", distribution boards, marshalling panels for
interface with 10S", etc. The other factors, which determine the si!e of sub-station, are the si!e,
rating, number and the arrangement of transformers outside the sub-station and whether the
connection from the transformers to the switchgear is through bus ducts or cables. The si!e of the
sub-station has to be determined early during the pro.ect and gi#en to the ci#il department for
designing the building.
*. How do we determine the best location for the sub)station?
/ sub-station in a process plant houses switchgears, motor control centers and distribution boards
besides other equipment", which recei#e power from one or more sources and distributes the same
to #arious consumers. The location of the sub-station should be optimally selected, such that it is
near to the area ha#ing maximum number of electrical consumers, and also as near to the source
of power #i!. the terminal pole of the transmission line, in-plant generators or nearest to the point of
entry of the cables from another sub-station", as possible. The abo#e two criteria are contradictory
to each other in requirements and the ultimate location needs .udgment and sometimes a study to
work out the most economical option.
+. ,o we need outdoor sub)station or switchyards?
3ormally indoor switchgears are generally a#ailable up to $$k% or sometime up to ''k%" #oltage
grade, beyond which one may ha#e to plan for outdoor switchgear. -hen incoming power is
recei#ed by o#erhead transmission lines, these can be directly connected to the incoming bay of the
switchyard from the terminal last" pole.
-. .hould we plan for underground cables or overhead cabling?
The cables inside a plant can either be buried in the soil, laid in built-up concrete trenches on cable
trays placed on steel supports or laid abo#e ground, either on pipe racks or sleepers" or cable
racks. There are ad#antages, disad#antages with all the systems. Underground cables could be
exposed to spillages in a process plant, which may o#er a period harm the cable outer .acket. 4n
addition maintenance say, in case of cable fault" or laying a new cable due to plant growth, may be
difficult in case of buried cables. /bo#e ground cables could be exposed to U% radiation from
sunlight, which may discolor and affect the cable outer .acket, requiring pro#ision of cable tray
co#ers for the cable tray in the upper most tier.
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1$. ,o we need a separate battery room inside a sub)station?
The most commonly used batteries are of lead acid type or nickel cadmium type. These batteries,
when a#ailable in #ented type construction, release hydrogen gas during charging, which forms a
highly explosi#e mixture with atmospheric oxygen. 4n #iew of this, these batteries cannot be kept
with other electrical equipment in the main sub-station room. 6ence, a separate battery room is
pro#ided, complete with an adequately si!ed exhaust fan to remo#e the potentially ha!ardous
explosi#e mixture and keep its concentration to the minimum, in the battery room atmosphere". /ll
electrical fittings and fixtures, like lighting fixtures, receptacles, etc., should be suitable for
ha!ardous atmosphere, with gas group category for hydrogen. 6owe#er, if the batteries are in %al#e
7egulated (ead /cid Sealed 8as 7ecombination" type construction, a separate room is not
required, as the products of chemical reaction during charging, recombine to form water. 4n such a
case, the sealed batteries can be e#en located in sheet steel cabinets if number and si!e permits",
along with their charges and Uninterruptible 2ower Systems U2S".

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